Brinkmann ProSeries 4495 User manual

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OWNER’S MANUAL
WARNING
HAZARDOUS EXPLOSION MAY RESULT IF THESE WARNINGS AND
INSTRUCTIONS ARE IGNORED. READ AND FOLLOW ALL WARNINGS AND
INSTRUCTIONS IN THIS MANUAL TO AVOID PERSONAL INJURY, INCLUDING
DEATH OR PROPERTY DAMAGE.
ASSEMBLY AND OPERATING INSTRUCTIONS
SAVE THIS MANUAL FOR FUTURE REFERENCE
NOTICE TO INSTALLER:
LEAVE THESE INSTRUCTIONS
WITH THE GRILL OWNER FOR
FUTURE REFERENCE.
Heavy-Duty
Gas Grill

1
WE WANT YOU TO ASSEMBLE AND USE YOUR GRILL AS SAFELY AS POSSIBLE.
THE PURPOSE OF THIS SAFETY ALERT SYMBOL IS TO ATTRACT YOUR
ATTENTION TO POSSIBLE HAZARDS AS YOU ASSEMBLE AND USE YOUR GRILL.
WHEN YOU SEE THE SAFETY ALERT SYMBOL
PAY CLOSE ATTENTION TO THE INFORMATION WHICH FOLLOWS!
READ ALL SAFETY WARNINGS AND INSTRUCTIONS CAREFULLY
BEFORE ASSEMBLING AND OPERATING YOUR GRILL.
DANGER
IMPORTANT SAFETY
WARNINGS
FOR YOUR SAFETY:
IF YOU SMELL GAS:
1. Shut off gas to the appliance at the LP cylinder and burners.
2. Extinguish any open flame.
3. Open the Lid.
4. If odor continues, leave the area and immediately call your gas supplier or your fire department.
FOR YOUR SAFETY:
1. DO NOT store or use gasoline or other liquids with flammable vapors in the vicinity of this or
any other appliance.
2. An LP cylinder not connected for use shall not be stored in the vicinity of this or any other
appliance to avoid the possibility of explosion.
• DO NOT store a spare LP gas cylinder under or near this appliance.
• Never fill the cylinder beyond 80% full.
• A fire causing death or serious injury may occur if the above is not followed exactly.
WARNING
DANGER

2
General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation and LP Cylinder Specifications and Safe Use. . . . . . . . . . . . . . 4–6
Connecting LP Cylinder and Hose / Regulator to Grill . . . . . . . . . . . . . . . . 6–7
Leak Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9
Pre-start Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lighting Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–12
Operating Grill and Helpful Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–15
Proper Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–17
Transporting and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19–20
Parts List and Assembly Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21–33
Grilling Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
TABLE OF CONTENTS
DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING: Be alert to the possibility of serious bodily injury if the instructions are not followed. Be sure to read and
carefully follow all of the messages.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

3
WARNING
• Never use natural gas in a unit designed for liquid propane gas.
• Never use charcoal briquets or lighter fluid in a gas grill.
• Leak test all connections before first use, even if grill was purchased fully assembled and after
each tank refill.
• Never check for leaks using a match or open flame.
CAUTION! Strong odors, colds, sinus congestion, etc. may prevent the detection of
propane. Use caution and common sense when testing for leaks.
• Always keep your gas grill free and clear of gasoline, paint thinner, or other flammable vapors
and liquids or combustible materials.
• Always check the grill prior to each use as indicated in the "Pre-Start Check List" section of this
manual.
• DO NOT use back rotisserie burner when main burners are in use.
•DO NOT obstruct the flow of combustion or ventilation air.
• Never place more than 15 pounds on the side burner. DO NOT lean on the side burner shelf.
• Keep children and pets away from hot grill. DO NOT allow children to use or play near this grill.
• DO NOT leave the grill unattended while in use.
• DO NOT allow the gas hose to come in contact with hot surfaces.
• DO NOT allow grease from drain hole to fall on hose or valve regulator assembly.
• Keep any electrical supply cords away from water or heated surfaces.
• Keep a fire extinguisher on hand acceptable for use with gas products. Refer to your local
authority to determine proper size and type.
• For household use only. DO NOT use this grill for anything other than its intended purpose.
• DO NOT use while under the influence of drugs or alcohol.
• Grill is hot when in use. To avoid burns:
• DO NOT attempt to move the grill.
• Lock the wheels so the unit does not accidentally move.
• Wear protective gloves or oven mitts.
• DO NOT touch any hot grill surfaces.
• DO NOT wear loose clothing or allow hair to come in contact with grill.
USE CAUTION AND COMMON SENSE WHEN OPERATING YOUR GAS GRILL.
FAILURE TO ADHERE TO THE SAFETY WARNINGS AND GUIDELINES IN THIS
MANUAL COULD RESULT IN SEVERE BODILY INJURY OR PROPERTY DAMAGE.
SAVE THIS MANUAL FOR FUTURE REFERENCE.
GENERAL WARNINGS

4
WARNING
WARNING
LP GAS CYLINDER (NOT SUPPLIED WITH THIS GRILL)
The LP cylinder is available for purchase at the same location the grill was purchased.
The LP (Liquid Propane) gas cylinder specifically designed to be used with this grill must have
a 20 lb. (9.1 kg) capacity incorporating a Type 1 cylinder valve and an over-filling protection
device (OPD).
• DO NOT connect this grill to an existing #510 POL cylinder valve with Left Hand threads. The
Type 1 valve can be identified with the large external threads on the valve outlet.
• DO NOT connect to a propane cylinder exceeding this capacity.
• DO NOT connect to a cylinder that uses any other type of valve connection device.
INSTALLATION INFORMATION:
The installation of this appliance must be in accordance with:
All applicable local codes, or in the absence of local codes, either:
• National Fuel Gas Code ANSI Z223.1 NFPA 54
• Natural Gas and Propane Installation Code: CAN/CGA B149.1
• Natural Gas Installation Code: CAN/CGA B149.1 (Canada)
• Propane Installation Code: CAN/CGA B149.2 (Canada)
To check your local codes, see your local LP gas dealer or natural gas company. This grill was not
intended to be connected to a natural gas supply line. If an external electrical source is utilized, it
must be electrically grounded in accordance with local codes, or in the absence of local codes, with
the National Electrical Code, ANSI/NFPA 70, or the Canadian Electrical Code, CSA 22.1.
• FOR OUTDOOR USE ONLY. DO NOT operate indoors or in an enclosed area such as a garage,
shed or breezeway.
• Use your grill OUTDOORS in a well ventilated space away from dwellings or other buildings to
prevent dangers associated with gas accumulation and toxic vapors. We recommend your grill
be situated at least 10 feet (3.1 m) from buildings.
• Maintain a minimum clearance of 24 inches (61 cm) between all sides of grill and walls or other
combustible material. DO NOT use grill under overhead unprotected combustible construction.
• DO NOT use or install this grill in or on a recreational vehicle and/or boat.

5
The cylinder must also be equipped with:
• A shut-off valve terminating in a Type 1 gas cylinder valve outlet.
• A Type 1 valve that prevents gas flow until a positive seal is obtained.
• An arrangement for vapor withdrawal.
• A collar to protect the cylinder shut-off valve.
• A safety relief device having direct communication with the vapor space of the cylinder.
• A listed over-filling prevention device (OPD).
• Turn off the cylinder valve when your grill is not in use.
• Handle the tank with care.
• Always secure the cylinder in an upright position.
• Never connect an unregulated LP gas cylinder to your grill.
• DO NOT expose LP gas cylinders to excessive heat or ignition sources.
• DO NOT store a spare LP gas cylinder under or near your grill.
• Allow only qualified LP gas dealers to fill or repair your LP gas cylinder.
• DO NOT allow the cylinder to be filled beyond 80% capacity.
• Read and follow all warnings and instructions that are on the cylinder and that accompany
this product.
• Never store a spare LP gas cylinder under or near your grill. This could cause excess pressure
to be expelled through the vapor relief valve resulting in fire, explosion, or severe personal
injury including death.
NOTE: PROPANE GAS IS HEAVIER THAN AIR AND WILL COLLECT IN LOW AREAS.
PROPER VENTILATION IS EXTREMELY IMPORTANT.
• Keep the ventilation opening(s) of the LP gas cylinder enclosure free and clear from
obstructions and debris.
• DO NOT insert any foreign objects into the valve outlet. Damage to the back-check could
result. A damaged back-check can cause a leak, possibly resulting in explosion, fire, severe
bodily harm, or death.
WARNING
DANGER
CYLINDER SPECIFICATIONS:
When purchasing or exchanging a cylinder for your gas grill, it must be constructed and marked in
accordance with the specifications for LP gas cylinders of the U.S. Department of Transportation
(DOT) or the National Standard of Canada, CAN/CSA-B339 Cylinders, Spheres and Tubes for
Transportation of Dangerous Goods; and Commission, as applicable; and provided with a listed
over-filling prevention device (OPD), and provided with a cylinder connection device compatible with
the connection for outdoor cooking appliances.

FILLING THE LP GAS CYLINDER:
• Allow only qualified LP gas dealers to properly fill or repair your LP gas cylinder.
• New tanks should be purged prior to filling; inform LP gas dealer if you are using a new tank.
• DO NOT allow the cylinder to be filled beyond 80% capacity. Over-filled tanks can create a
dangerous condition. Over-filled tanks can build-up pressure and cause the relief valve to expel
propane gas vapors. The vapor is combustible and if it comes in contact with a spark source or
flame an explosion causing severe burns, bodily harm, or death could occur.
• Always use a protective cylinder cap when grill is not connected to cylinder.
• If you exchange a cylinder with a qualified exchange program, be sure the cylinder has
a Type 1 valve and an over-filling prevention device (OPD).
INSTALLING THE LP GAS CYLINDER ONTO THE GRILL:
1. Check that the cylinder valve is closed by turning the knob
clockwise.
2. Place the cylinder into the tank holder in the bottom
of cabinet.
3. Orient the cylinder such that the valve opening faces the
side burner, and so that the hose is not kinked or damaged.
4. Fully tighten the cylinder clamp underneath tank holder to
secure tank.
5. Attach or detach regulator to the LP gas cylinder only
when cylinder is at rest in tank holder.
HOSE AND REGULATOR:
Your grill is equipped with a Type 1 connection device with
the following features:
1. The system will not allow gas flow from the cylinder until
a positive connection to the valve has been made.
NOTE: The cylinder valve must be turned off before any
connection is made or removed.
2. A thermal device that will shut off the gas flow if the device is
subject to temperatures above 240°F to 300°F (115°C to
150°C). If this should happen, remove the entire regulator
assembly and dispose of properly. A replacement regulator
assembly can be purchased by contacting customer service
at 800-527-0717. The cause of the excessive heat should be
determined and corrected before using your grill again.
3. A regulator flow limiting device, when activated, restricts the
flow of gas to 10 cubic feet per hour. If the flow limiting
device is activated, perform Regulator Resetting Procedure.
WARNING
6
Tank Holder
Cylinder Clamp
REGULATOR RESETTING PROCEDURE
1. Turn burner control knobs to "OFF”, turn off the cylinder valve and disconnect regulator from LP gas
tank. Wait approximately two minutes.
2. Reattach regulator and slowly turn cylinder valve back on. The flow limiting device will now be reset.

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WARNING
• Never use your grill without leak testing all gas connections and hoses. See the section on
"Leak Testing" in this manual for proper procedures.
The pressure regulator and hose assembly supplied with your gas grill must be used.
• DO NOT attempt to connect it to any other fuel supply source such as a natural gas line.
• DO NOT use any other pressure regulator/hose assembly other than the one supplied with your grill.
Replacement pressure regulator/hose assembly must be part No 155-4775-0, which can be obtained
by contacting customer service at 800-527-0717.
• DO NOT attempt to adjust or repair the regulator. The regulator is designed to operate at a
maximum output pressure of 11 inches of water column (2.74 kPa).
During assembly and/or replacement of the gas cylinder, keep the gas supply hose free of kinks
and/or damage.
Visually inspect the hose assembly prior to each use for evidence of damage, excess wear, or
deterioration. If found, replace the assembly before using your grill. Only the manufacturer's supplied
replacement should be used.
CONNECTING HOSE AND REGULATOR TO AN LP GAS CYLINDER
• Ensure the tank valve is CLOSED prior to connecting the LP gas cylinder to your grill. Turn the
valve knob clockwise to properly close the valve. Read and follow all instructions and warnings
on the supply hose safety tags. Read and follow all warnings in this manual concerning the safe
use of LP gas cylinders and the hose and regulator before connecting cylinder to grill. Read
and follow all warnings on the LP cylinder.
CONNECTING HOSE AND REGULATOR
1. Check that the cylinder valve is closed by turning the knob clockwise.
2. Check that the grill’s burner control knobs are in the "OFF" positions.
3. Remove the protective plastic cap from the cylinder valve and the connection device.
4. Hold regulator and insert the nipple of connection device into the LP cylinder valve outlet. Ensure that
the device is centered properly.
5. Turn the large coupling nut clockwise by hand and tighten to a full stop. Take care not to cross thread
the coupling nut onto the cylinder valve. Do not over-tighten the knob onto the valve. Do not use tools
to tighten connection.
NOTE: If you are unable to make the connection, repeat Steps 4 and 5.
6. Check that the hose does not contain kinks, does not contact sharp edges, and does not contact
surfaces that may become hot during use.
7. Leak check all fittings before lighting your grill. See section on "Leak Testing" in this manual.
WARNING
WARNING

LEAK TESTING:
To prevent fire or explosion hazard:
• DO NOT smoke or permit ignition sources in the area while conducting a leak test.
• Perform test OUTDOORS only in a well ventilated area.
• Never perform a leak test with a match or open flame.
• Never perform a leak test while the grill is in use or while grill is still hot.
WHEN TO PERFORM A LEAK TEST:
• After assembling your grill and before lighting for the first time, even if purchased fully assembled.
• Every time the LP gas cylinder is refilled or if any of the gas components are replaced.
• Any time your grill has been moved.
• At least once per year or if your grill has not been used for more than 60 days.
CHECKING FOR LEAKS:
1. Create a mixture of 50% water and 50% liquid dishwashing soap.
2. Open the lid.
3. Ensure all control knobs are set to the "OFF" position.
4. Turn on the fuel supply at the cylinder valve. Turn the
cylinder valve knob one turn counter-clockwise.
5. Apply the soap water mixture to the following:
Supply tank (cylinder) weld.
Connection nut to tank valve.
Back side of connection nut to brass
nipple.
Brass nipple connection into regulator.
Regulator connections to gas supply hoses.
Hose connection to gas manifold.
The full length of gas supply hose.
Tank valve to cylinder.
H
G
F
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D
C
B
A
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WARNING
Watch For Bubbles
DANGER
A
B
C
D
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F
G
H

WARNING
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6. Check each place listed (A– H) for growing bubbles which indicates a leak.
7. Turn off gas supply at cylinder valve.
8. Turn on control knobs to release gas pressure in hose.
9. Turn control knobs to "OFF" position.
10. Tighten any leaking connections.
11. Repeat soapy water test until no leaks are detected.
12. Turn off gas supply at cylinder valve until you are ready to use your grill.
13. Wash off soapy residue with cold water and towel dry.
14. Wait 5 minutes to allow all gas to evacuate the area before lighting grill.
CAUTION!DO NOT use the grill if leaks cannot be stopped. Contact a qualified gas appliance
repair service.
NOTE: The leak test must be performed in an area that has adequate lighting in order to see if
bubbles are developing. DO NOT use a flashlight to check for bubbles.
PRE-START CHECK LIST:
Property damage, bodily harm, severe burns, and death could result from failure to follow these
safety steps. These steps should be performed after the grill has been assembled and prior to each
use. DO NOT operate this grill until you have read and understand ALL of the warnings and
instructions in this manual.
PRE-START CHECK LIST:
•Ensure that the grill is properly assembled.
•Inspect the gas supply hose for burns, chaffing, kinks, and proper routing before each use. If it is
evident there is excessive abrasion or wear, or the hose is cut, it must be replaced prior the grill being
used. Replace with hose and regulator, Model No. 155-4775-0, which can be obtained by contacting
customer service at 800-527-0717.
•Leak check all gas connections and hose. See section on "Leak Testing".
•Ensure that all electrical supply cords are properly grounded. Keep any electrical supply cord and the
fuel supply hose away from any heated surfaces. Hose should be at least 3 inches from hot surfaces.
•Position your grill on level ground in a well ventilated location, a safe distance from combustible
materials, buildings and overhangs.
•Properly place the empty grease tray under the grease drain hole in the bottom of the
grill to catch grease during use.
• DO NOT obstruct the flow of combustion and ventilation air.